Corrugated bathtub package

ABSTRACT

A shipping container for a bulky item, such as a bathtub or the like, which is formed entirely from corrugated paperboard material. A wrap-around body portion is provided in combination with a pair of corrugated end closures which incorporate build-up blocks to suspend the bathtub within the body portion and close the ends of the body portion to completely enclose the bathtub for shipping.

United States Patent Edsall [451 Nov. 20, 1973 [54] CORRUGATED BATHTUBPACKAGE 1,852,832 4/1932 Beaman 229/14 C [75] Inventor. Robert N.Edsall, Saline, Mich. 3,385,502 5/1968 73 Assigneez OwensJllinois, Inc.Toledo i 3,680,688 8/1972 Smith 206/46 H [22] Filed: May 19, 1972 Appl.No.: 255,148

Primary ExaminerDavis T. Moorhead Attorney-Alan J. Steger et a1.

[57] ABSTRACT A shipping container for a bulky item, such as a bathtubor the like, which is formed entirely from corrugated paperboardmaterial. A wrap-around body portion is provided in combination with apair of corrugated end closures which incorporate build-up blocks tosuspend the bathtub within the body portion and close the ends of thebody portion to completely enclose the bathtub for shipping.

1 Claim, 8 Drawing Figures PATENIEUnuvzo I975 SHEET 10F 3 E m 4 2 o DJ nl wy 2 IBM A U I 1 n. F m m l 1w w m m 4 fl H LH G /0 0 MW /lfi 2H1 6 r2 4 id 5 m 5 A s I (0 mfi v 5 8 m M mw Z FIG.

PATENTEU NUY P 0 I975 SHUT 3 {F CORRUGATED BATI-ITUB PACKAGE BACKGROUNDOF THE INVENTION This invention relates to containers and, moreparticularly, relates to a container constructed of fibrous materialsuch as corrugated paperboard or the like and which may be folded orcollapsed for shipping or storage and unfolded and set up as needed.

It is very desirable to have an inexpensive container suitable forpackaging large, bulky items, such as bathtubs, metal cabinets, etc.Suitable containers for such large, bulky items have typically beenrather expensive due to the high storage characteristics necessary tocontain such products. In general, bathtubs, for example, have beenshipped in heavy wooden crates or in paperboard containers which werereinforced by means of wooden or metal support inserts. These woodencontainers or paperboard containers reinforced with wooden or metalinserts are not only extremely heavy and cumbersome, but expensive, bothfrom the standpoint of material cost and the assembly time involved.

Hence, there is a significant need for and it is an object of thisinvention to provide an inexpensive, lightweight container formedentirely from corrugated paperboard which is adapted for packaging andshipping large, bulky items such as bathtubs. Other objects, features,and advantages of this invention will become obvious to those skilled inthe art upon reference to the following detailed description and thedrawings illustrating a preferred embodiment thereof.

IN THE DRAWINGS:

FIG. 1 is a plan view of a paperboard blank adapted to be folded to formthe main body portion of the subject container.

FIG. 2 is a perspective view of an end closure member including build-upblocks which is adapted to close one end of the main body portion ofFIG. 1.

FIG. 3 is a perspective view of the main body portion of FIG. 1 and apair of-end closure members of FIG. 2 in a partially assembledrelationship with a bathtub.

FIG. 4 is a perspective view of the main body portion and end closuremembers of FIG. 3 in the completely assembled portion.

FIG. 5 is a partial sectional view taken in the direction of arrows AAin FIG. 4.

FIG. 6 is a partially cut-away sectional view showing the relationshipof the bottom support build-up block of the end closure member and acorner of the bathtub.

FIG. 7 is a partially cut-away sectional view showing the relationshipof the upper rim portion of the bathtub with respect to the rim engagingbuild-up block of the end closure members.

FIG. 8 is a perspective view showing a pop-in corner which is formed inthe main body portion.

SUMMARY OF THE INVENTION In general, this invention provides asubstantially rigid container which may be constructed of a fibrousproduct, such as corrugated paperboard, and which is adapted to hold arather large, bulky product, such as a bathtub. More specifically, thisinvention provides a three-piece shipping container for a bathtub whichis formed entirely from corrugated paperboard material. A wrap-aroundbody portion is provided with a pair of end closure members whichincorporate build-up blocks which suspend the bathtub within the bodyportion and close the ends of the body portion to completely enclose thetub. The end closure members incorporate a grooved upper build-up blockwhich is adapted to be inserted over the upper rim of a bathtub tosecurely position each end of the bathtub. In addition, the end closuresincorporate a build-up block portion which is adapted to extend underthe lower comers of a bathtub for supporting it within the main bodyportion of the container. Once the end closures have been inserted intoengagement with the bathtub, the wraparound main body portion is set upand folded into encircling relationship with the bathtub and stapled tothe end closures to completely enclose the bathtub. Thus, a largerectangular shipping container is provided which exhibits sufficientrigidity and strength properties to make it well suited for containingand shipping a large, bulky item, such as a bathtub, but which is alsolight in weight and inexpensive when compared with wooden crates orpaper-board containers utilizing wooden or metal reinforcements used forthe same purpose.

DESCRIPTION OF A PREFERRED EMBODIMENT More particularly, FIG. 1 shows abox blank 10 which has been scored and sized so as to make it foldableinto a main body portion, indicated generally by the numeral 12 in FIGS.3 and 4. The box blank I0 is seen to include a front panel 14, a bottompanel 16, a back panel 18, a top panel 20, and a closing flap 22 all ofwhich are hingedly connected along suitable score lines 24. Formed alongthe opposite edges of these panels are a pair of end engaging flaps 26and 28. These end engaging flaps 26 and 28 are connected to the variouspanel components along suitable score lines 30. The transformation ofthe box blank 10 into the main body portion 12 can best be understood byreference to the transition from FIG. 1 to FIG. 3 to FIG. 4. Each of thepanels 14, I6, 18, and 20 are folded degrees so as to be perpendicularto each other along their respective score lines 24 so that the opposedpanels 14 and 18 form the front and back, respectively, and the opposedpanels 16 and 20 form the bottom and top, respectively, of the main bodyportion 12. The closing flap 22 is then folded along its score line 24into engagement with the front panel 14 so that it can either bestitched or stapled to the front panel 14 to secure the main bodyportion 12 into set-up condition. It is suggested that the closing flap22 be tucked into engagement with the interior side of front panel 14 asshown in FIG. 5. It should be understood that the main body portion 12of this invention is well suited to form a wrap-around container for anumber of bulky items; however, for the purposes of illustration, it isdescribed in its preferred embodiment as being adapted to form ashipping container for a bathtub 32.

FIG. 2 shows one of a pair of end closure and bathtub supporting members34 which are utilized in cooperation with the main body portion 12 toform a completed package. The end closure member 34 includes an endpanel 36 and four build-up blocks 38, 40, 42, and 44. Each of thesebuild-up blocks is formed from a plurality of layers of corrugatedpaper-board which have been adhesively joined together and then die cutto provide a desired shape. The upper build-up block 44 incorporates agroove or recess 46 which is adapted to fit over an upper rim 418 on thebathtub 32. The vertically extending build-up blocks 38 and 42 arepositioned and attached to the end panel 36 so as to provide verticalsupport to the resulting container and abut the end portions of thebathtub 32. The remaining build-up block 40 is positioned to the lowercorner of the end panel 46 and is shaped to provide a supporting surface50 for the lower edge of the bathtub 32. Each end panel 36 also includesa pair of hand-holding cutouts 52 which facilitate easy handling of theresulting package. While the end closure member 34 illustrated in FIG. 2is shaped and sized to perform as the end closure member shown at thefront edge of FIG. 3, it should be understood that the end closuremember at the opposite end of the bathtub 32 is virtually identical tothe end closure member 34.

A further feature of the main body portion 12 can be understood byreference to FIGS. 1 and 3. In FIG. 1 it can be seen that the box blankI includes a pair of pop-in corners 54 formed by means of a pair ofparallel slits 56 which are perpendicular to and overlap the score line24 between front panel 14 and bottom panel 16. These pop-in corners 54are pushed inwardly when the main body portion is assembled to theposition shown in FIG. 4 so as to abut build-up block 38 and providelateral support for the end closure member 34 at the front corners ofthe bathtub 32.

When it is desired to package a bathtub, such as the one indicated bythe numeral 32 in this illustration, a pair of the end closure members34 are first placed into engagement with the opposite ends of thebathtub 32. As can be seen in FIG. 3, each end closure member 34 ispositioned over the upper edge of the bathtub 32 so that the rim 48resides within the groove 46 in the upper build-up block 44 of endclosure member 34$. This relationship can best be seen by reference toFIG. 7. When placed in position, the lower build-up block 40 of endclosure member 34 rests under the back edge of the bathtub 32 so thatthe bathtub 32 is supported on the surface 50. This supportingrelationship can best be seen by reference to FIG. 6. The verticallyextending build-up biock 42 serves as an external support and separatoralong the back edge of the bathtub 32 and the vertically extendingbuild-up block 38 provides vertical support to the front edge of thebathtub 32.

Once the end closure members 34 have been placed into engagement withthe bathtub 32, the bathtub 32 maybe positioned in overlyingrelationship with respect to the box blank so that the bottom edges ofthe end closure members 34 rest directly on the bottom panel 16 as shownin FIG. 3. It should also be understood that the bathtub 32 may bepositioned over the bottom panel 16 of the box blank 10 prior to theattachment of the end closure members 34. The box blank I6 is thenfolded as viewed in FIG. 3 so that the front panel 14, back pnael 18,and top panel 20 assume their proper locations as shown in FIG. 4. Thetop closing flap 2 may then be tucked into contact with the inside ofthe front panel 14 and stitched or stapled thereto to assume the closedposition shown in FIGS. 4 and 5. The end engaging flaps 26 and 28 arethen folded along their respective score lines 30 into overlyingrelationship with respect to the end closure members 34 as shown in FIG.4. These end engaging flaps 26 and 28 may then be either stapled orstitched to the end closure members 34 to form the completed shippingcontainer for the bathtub 32. As a last step, the pop-in corners S4 maybe pushed inwardly as shown in FIG. 8 so that they engage, respectively,vertical buildup blocks 38 and 42 to provide additional lateral supportat the front edges of the bathtub 32.

Therefore, as can be seen from the above description, a relativelysimple, yet substantially rigid container is provided by this inventionwhich is formed entirely from corrugated paperboard and yet is wellsuited for packaging a bulky item, such as bathtub. Since the entirepackage is formed from corrugated paperboard material, it isconsiderably less expensive and lighter in weight than previously usedcontainers formed entirely from wood or incorporating portions formedfrom wood or metal. In addition, the bathtub is better protected becauseof the natural cushioning properties of the corrugated paperboardmaterial. Furthermore, the unique relationship of the end closuremembers utilizing corrugated build-up blocks to completely suspend thebathtub inside the outer wrapper further insulates the bathtub fromdamage during packaging warehousing, handling, and shipping. The uniquepackages of this invention are designed so that they will nest togetherfor shipment and also can be stacked for storage in a warehouse.

I claim:

1. A folded paperboard container for a bathtub comprising:

substantially rectangular wrap-around body means including a frontpanel, a bottom panel, a back panel, a top panel, and a closing flapadapted to be folded perpendicular to said top panel and attached tosaid front panel and having end closure engaging flaps formed on andhingedly connected to the opposite ends of said front panel, said bottompanel, said back panel, and said top panel, said back panel being formedbetween and integral with said top and bottom panels and said frontpanel being formed integral with and positioned adjacent to the oppositeside of said bottom panel;

a pair of substantially rectangular end closure members engaging andsupporting opposite ends of the bathtub and being attached to said endclosure engaging flaps to completely enclose said bathtub, said pair ofend closure members each including an end panel to which said endclosure engaging flaps are attached and a plurality of paperboardbuild-up block portions which are attached to said end panel and engageand support the opposite ends of said bathtub, said build-up blockportions on eacn of said pair of end closure members including an upperbuild-up block incorporating a groove therein into which an upper rim onthe end of said bathtub may be inserted, a lower build-up blockincorporating a supporting surface for supporting a lower edge on theend of said bathtub, and a pair of vertical-extending build-up blocksengaging the ends of said bathtub, said end panels on each of said pairof end closure members including a pair of hand-holding cutout aperturesfor use in handling said container;

and a pop-in corner being formed in said body means at each end of thefold between said front panel and said bottom panel by means of a pairof parallel slits which extend from said front panel into said bottompanel so that the pop-in corners can be pushed into engagement with saidpair of vertically-extending build-up blocks on said end closuremembers.

i s i t UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3 773 171 Datedwzg ]913 Invent r( ROBERT N. EDSALL It is certified thaterror appears in the above-identified patent and that said LettersPatent are hereby corrected as shown below:

Col. 3, line 54, "pnael 18" should be panel l8-; Col. 3, line 56, "flap2" should be flap 22. C01. 4, line 7, af-

ter "such as" insert -a; Col. 4 line 47 (Claim 1) ll ea'Crlll should be-each.

Signed and sealed this 25th day of June 197A.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. C. MARSHALL DANN Attesting Officer Commissioner ofPatents )RM PO-IOSO (10-69) USCOMM-DC 60376-P69 r us. GOVERNMENTPRINTING OFFICE: 1969 o-ass-au.

1. A folded paperboard container for a bathtub comprising: substantiallyrectangular wrap-around body means including a front panel, a bottompanel, a back panel, a top panel, and a closing flap adapted to befolded perpendicular to said top panel and attached to said front paneland having end closure engaging flaps formed on and hingedly connectedto the opposite ends of said front panel, said bottom panel, said backpanel, and said top panel, said back panel being formed between andintegral with said top and bottom panels and said front panel beingformed integral with and positioned adjacent to the opposite side ofsaid bottom panel; a pair of substantially rectangular end closuremembers engaging and supporting opposite ends of the bathtub and beingattached to said end closure engaging flaps to completely enclose saidbathtub, said pair of end closure members each including an end panel towhich said end closure engaging flaps are attached and a plurality ofpaperboard build-up block portions which are attached to said end paneland engage and support the opposite ends of said bathtub, said build-upblock portions on eacn of said pair of end closure members including anupper build-up block incorporating a groove therein into which an upperrim on the end of said bathtub may be inserted, a lower build-up blockincorporating a supporting surface for supporting a lower edge on theend of said bathtub, and a pair of vertical-extending build-up blocksengaging the ends of said bathtub, said end panels on each of said pairof end closure members including a pair of hand-holding cutout aperturesfor use in handling said container; and a pop-in corner being formed insaid body means at each end of the fold between said front panel andsaid bottom panel by means of a pair of parallel slits which extend fromsaid front panel into said bottom panel so that the pop-in corners canbe pushed into engagement with said pair of vertically-extendingbuild-up blocks on said end closure members.